Coating compositions for dough-based goods including doughnuts and other products

ABSTRACT

A food product including an edible substrate at least partially derived from dough or batter is provided. Such a food product includes a first water-soluble coating. The first coating includes a starch, a starch derivative, or a mixture thereof. The first coating at least partially covers the surface of the edible substrate prior to the application of a second coating. The substrate and the second coating have different water activities. The first coating provides at least a partial moisture barrier between the substrate and the second coating.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. patent application Ser. No. 10/682,672, filed Oct. 9, 2003, which claims the benefit of U.S. Provisional Patent Application No. 60/417,295, filed Oct. 9, 2002. This application is also a continuation-in-part of U.S. patent application Ser. No. 11/933,091, filed Oct. 31, 2007, which is a continuation of U.S. patent application Ser. No. 10/170,964, filed Jun. 13, 2002, now U.S. Pat. No. 7,294,355, which claims the benefit of U.S. Provisional Patent Application No. 60/305,005, filed Jul. 12, 2001, and claims the benefit of U.S. Provisional Patent Application No. 60/334,646, filed Nov. 30, 2001. The disclosures of each of the above applications are hereby incorporated by reference in their entireties.

BACKGROUND OF THE INVENTION

This invention generally relates to a coating compositions applied to the external surface of dough-based goods (at least partially derived from dough) including doughnuts and other products, typically wheat-based doughnuts.

Numerous different types of edible food coatings are known. These include relatively heavy and thick coatings of various materials (e.g., bread crumbs, potato batter, tempura, etc.) as well as various flour or starch-based coatings that are usually applied as a relatively thin batter thereby forming a much thinner coating, which can be substantially transparent after application to the food substrate. The thinner coatings are then cooked, further cooked if parfried, or otherwise thermally processed. This latter type of coating is extensively used on commercially prepared french fry potatoes, where they are often referred to as “clear coats” due to their unobtrusive and, in some cases, virtually unnoticeable visual characteristic. Traditionally, clear coats formulated for french fry products do not adhere effectively to wheat based substrates, such as pastries or dough.

It is also known to use clear glazes on dough-based baked goods such as doughnuts and the like. The glazes may be applied either before or after baking. While generally sugar-based glazes are applied to impart shine and eye appeal, they tend to become wet and sticky. Still other glazes have been used to impart softness to the surface of a baked or fried good, such as doughnuts.

Doughnuts have been known since at least about the mid-19^(th) century. A doughnut is typically a small, usually ring-shaped dough fried in fat. Yeast raised and cake doughnuts are typically fried dough products traditionally having a sugar glaze applied to the surface. The dough portion of the finished product typically has a water activity of from about 0.8 to about 9.5 whereas the glazed portion of the finished product typically has a water activity of less than about 0.7. Water activity is a measure of how much water is bound within a product matrix that is unable to migrate and take part in reactions or be available for microorganisms. The water activity of pure water is 1.0. In food systems or products where two or more distinct components that have different water activities are combined, as in glazed doughnuts, there will be a migration of moisture from the area of higher water activity to the area of lower water activity until equilibrium is reached. When this happens in traditional glazed doughnuts, the moisture from the dough portion migrates to the glazed portion and causes the sugar ingredients in the glazed portion to dissolve, become wet and liquefy. The time it takes for the glaze to liquefy as a result of this migration is typically the determining factor for identifying the shelf-life of the finished doughnut product. Generally, doughnuts available in the retail market generally have a shelf-life of from about 6 hours to about 2 days depending upon the relative humidity in the given marketplace, more typically such doughnuts have a shelf-life of from about 8 hours to about one day.

Food coating moisture barriers are typically either water-soluble or solvent-soluble. The more water-soluble a film or barrier, usually the film or barrier becomes more permeable to water vapor. The solvent-soluble barriers are typically the best moisture barriers (e.g. shellac) because water vapor does not pass through them as readily. Shellac is a resinous secretion called lac, of the insect Liaccifen lacca. Shellac is not water-soluble and is generally considered a glaze and a surface finishing agent. However, solvent-soluble barriers possess a major disadvantage, namely, they are solvents. Food manufacturers have to ensure that the solvent exhausted from their facilities is regulated since it contributes to the total volatile organic compounds (VOCs). The United States Environmental Protection Agency tightly regulates VOCs, especially in more populated urban areas.

Another known type of coating utilizes a food grade wax dispersed in vegetable oil. This type of coating is most often used on pizza crusts and meat pies to prevent moisture in the sauce or filling, respectfully, from leaching into the crust or shell. This coating is not water soluble, requires hot water detergents for cleaning, and significantly increases the fat content of the finished product.

Accordingly, there is a need for water-soluble, moisture barrier compositions that (1) can be applied to the surface of doughnuts or other pastry products before glaze or other coating application and (2) form at least a partial barrier to moisture transfer that otherwise occurs between the dough portion and the glazed or other coated portion of the finished product when water activity gradients are present.

SUMMARY OF THE INVENTION

The present invention goes well beyond prior art technology in both the nature and use of thin, edible food coatings by providing coating formulations and application procedures that enable the coatings to be applied either in a slurry state or a dry solid state and either before or after thermal processing of the dough-based good(s) such as a doughnut. The present invention includes a coating that includes starch where the coating is in dry or slurry form that can be applied to the surface of a doughnut or other dough-based product either before or after the doughnut is processed, typically by frying, prior to a glaze or other coating application. The starch mixture provides at least a partial moisture barrier that at least partially prevents moisture transfer that would otherwise occur between the dough portion and the glaze portion due to the different water activities of the dough portion and the glaze portion. The coating provides significantly extended shelf-life to doughnuts over typical doughnuts without such a moisture barrier. The present invention also relates to dough-based products, typically doughnuts and the like, produced utilizing the coating compositions of the present invention and methods of producing the dough-based, coated products.

These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart depicting an embodiment of the process of applying the water-soluble moisture barrier wet slurry composition to raw dough before or after proofing according to the present invention;

FIG. 2 is a flow chart depicting an embodiment of the process of applying the water-soluble moisture barrier wet slurry composition to a fried doughnut according to the present invention;

FIG. 3 is a flow chart depicting an embodiment of the process of applying the water-soluble moisture barrier wet slurry composition to a fried, cooled, and then reheated doughnut according to the present invention;

FIG. 4 is a flow chart depicting an embodiment of the process of applying the water-soluble moisture barrier composition, typically by dusting, to raw dough before or after proofing according to the present invention;

FIG. 5 is a flow chart depicting an embodiment of the process of applying the water-soluble moisture barrier composition, typically by dusting, to a fried doughnut according to the present invention; and

FIG. 6 is a flow chart depicting an embodiment of the process of applying the water-soluble moisture barrier composition, typically by dusting, to a fried, cooled and then reheated doughnut according to the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

A doughnut is typically a small usually ring-shaped dough product most often cooked by frying in fat. Consumers may purchase a doughnut for immediate consumption, reheat then consume, or thaw and then consume. Typically, doughnut varieties include, but are not limited to glazed, filled, iced, cake and/or yeast dough-based, and/or flavored doughnuts, etc. Any flavor dough or coating may be employed. Doughnuts also include a variety of shapes, including but not limited to spherical mass (i.e. doughnut holes), O-shaped (i.e., a doughnut ring with a missing center), oval shaped, star shaped, etc. Typically, yeast raised doughnuts have lower moisture content than chemically raised doughnuts such as cake doughnuts, but the moisture barrier coating compositions of the present invention apply to both. However, due to the water activity difference, the coating is especially beneficial when providing a moisture barrier for yeast-raised doughnuts. However, the term “doughnut” is meant to encompass any dough-based or batter-based product that is fried or otherwise thermally processed prior to consumption. Accordingly, the term doughnuts includes items such as elephant ears and funnel cakes.

The clear coat moisture barrier composition of the present invention is typically applied to the surface of the doughnut prior to application of a glaze or other coating. The clear coat water-soluble moisture barrier composition forms at least a partial, but more typically a substantially complete or complete water-soluble moisture barrier that substantially inhibits transfer of moisture that, absent the moisture barrier coating, otherwise occurs between the dough portion and the glazed or other coated portion of the finished product due to the difference in water activities between the dough portion and the glaze or other coating portion. “Water soluble” as used herein means the components are capable of being at least partially dissolved in water or are capable of being dispersed in water. The clear coat moisture barrier coating is typically substantially invisible to the consumer and thus will not detract from the appearance of the doughnut to which it is applied. Optionally, a colorant could be added, but this is usually not desired and, therefore, is not typically included in the formula. However, if one were to use a colorant, possible colorants include caramel, or any water dispersible food colorant or combination of food colorants.

By incorporating a moisture barrier between the dough portion and the glazed coated portion, the water migration to the glaze does not occur or is greatly limited. The moisture barrier offers many benefits including, but not limited to, extending the shelf-life of the glazed doughnuts. The shelf-life of glazed coated doughnuts can be extended from about 6 hours to 6 or more days. In this instance the shelf-life of the product is determined by the staling (hardening of the starch) within the doughnut and not wetting out of the glaze. Because of the clear coat moisture barrier glazed doughnuts have an increased shelf-life and because they are less affected by changes in humidity, there is no need for multiple and costly doughnut production facilities strategically placed throughout their marketplace. Rather, the moisture barrier coated glazed or other coated doughnuts may be produced in one location and then shipped to their final destinations without risk of staling within the time frame of past glazed doughnuts. This is a result of the significantly increased shelf-life of the goods, typically doughnuts, from about 8 hours to one day to about six or more days. Thus, through use of the inventive coating compositions this new distribution method for doughnuts utilizes fewer centralized facilities.

Additionally, an effective clear coat moisture barrier is achieved without the use of solvent-soluble films which are generally regarded as the most effective moisture barrier, but have strict United States Environmental Protection Agency regulations regarding their exhaust from production facilities. To the contrary, because the coating compositions of the present invention include starch and other water-soluble components, they are not strictly controlled and are not strictly regulated by the United States Environmental Protection Agency.

The water-soluble, clear coat moisture barrier composition of the present invention is typically applied as a wet slurry or as a dry dusting or a combination of the two on the doughnut or other dough-based goods. Either the wet slurry or any applications may be done before or after proofing and frying (FIGS. 1 and 4), on fried doughnuts (FIGS. 2 and 5) or on fried, cooled, then reheated doughnuts or other dough-based goods (FIGS. 3 and 6). It is presently believed that the water-soluble, clear coat composition of the present invention best forms a moisture barrier upon thermal processing or by its application to a warm or hot food substrate; however, heating or a hot surface is not presently believed to be a requirement for formation of the moisture barrier.

Additionally, the coating compositions can be applied at the source of consumer purchase. If the doughnuts are produced on-site or thawed after freezing, once thermally processed, the coating composition can be applied prior to coating with a glaze or other coating. Also, the doughnuts can be produced and coated and subsequently frozen in a liquid nitrogen freezer system such as those available from BOC Gases in Murry Hill, N.J. This allows the doughnuts to be thawed and a glaze applied either later at the same location, but more often at the end production facility such as a grocery store or doughnut store.

Moreover, the doughnut may be coated with the composition of the present invention, glazed and subsequently frozen. This allows for total production at one facility, easy distribution over a larger distance without spoilage, and surprisingly, when the finished product is thawed, there is no wetting out of the doughnut. In doughnuts without the coating composition of the present invention, wetting-out occurs at least 2-4 times as rapidly. It is presently believed that ice crystals, typically formed at the surface of the glaze, and condensation from ambient air humidity as the doughnut thaws are essentially pulled in and absorbed by the moisture barrier coating composition preventing wetting-out of the glaze upon thawing.

The doughnut substrate may also be coated with a coating composition of the present invention, frozen, thawed, and coated again prior to application of the glaze or other coating. A larger amount of the coating composition could also be applied prior to freezing to thereby provide a more complete moisture barrier to the food substrate upon thawing and application of the glaze.

Wet Slurry Typical Moisture Barrier Composition for Fried or Raw Dough Doughnuts

When the moisture barrier coating of the present invention is applied as a wet slurry on a fried doughnut, parfried, or to raw dough before or after proofing, the clear coat water-soluble moisture barrier composition may include the following ingredients: a modified potato starch; sodium acid pyrophosphate 28 (leavening agent); sodium bicarbonate (leavening agent); dextrin; sucrose (sweetening agent); gums (stabilizer); an emulsifier (granular lecithin); and flour, typically rice flour.

The modified (chemically or physically) potato starch is typically present in the moisture barrier slurry composition applied to raw dough before or after proofing or to a fried doughnut in an amount of from about 20% to about 90% by weight of the coating composition, more typically from about 40% to about 70%, and most typically at about 56.65%. The modified potato starch primarily provides film formation properties. Typically, the potato starch has been modified by any industrially acceptable modification means, including, but not limited to, crosslinking or substitution. Any suitable potato starch may be used whether modified or unmodified. In fact, it is presently believed that any starch may be utilized in the slurry composition of the present invention including corn starch, potato starch, tapioca starch, wheat starch or mixture thereof.

The moisture barrier wet slurry composition applied to a fried doughnut, a parfried doughnut, or to raw dough before or after proofing also may contain a leavening system, usually a two-component, acid/base leavening system. When utilized in the moisture barrier coating, the leavening system typically utilizes an acid in combination with a bicarbonate salt. When a leavening system is used, the sodium acid pyrophosphate (SAPP) or other acid is typically present in the range of from about 0% to about 4% by weight of the coating composition, more typically from about 0.5% to about 2.5%, and most typically about 1.0%. The bicarbonate salt typically includes sodium bicarbonate within the range of from about 0% to about 2% by weight of the coating composition, more typically from about 0.3% to about 1.5%, and most typically at about 0.7%. Any sodium bicarbonate or SAPP may be used in the present invention. The sodium acid pyrophosphate, in combination with sodium bicarbonate, provides chemical leavening that results in a lighter tender texture of the exterior of the doughnut. While a leavening system is typically employed in a slurry application of the coating of the present invention, use of a leavening system is optional.

The moisture barrier slurry compositions applied to raw dough before or after proofing or to a fried doughnut also typically includes a dextrin. The dextrin utilized may include corn dextrin, tapioca dextrin, potato dextrin, or any other commercially acceptable dextrin; however, corn dextrin is most typically used. The dextrin is believed to provide superior film forming functionality to the coating compositions when used to coat dough-based products over other dextrins. All dextrins are soluble to some degree; however, a low solubility dextrin is typically used in the moisture barrier composition for fried or raw dough doughnuts. The term “low solubility dextrin” typically means less than 32% of the dextrin is soluble when placed in cold water (approximately 77° F.). Further, to one of ordinary skill in this art, the term “low solubility dextrin” also generally refers to the solubility of a dextrin when compared to other dextrins. For example, a medium solubility dextrin typically exhibits from about 32% to about 90% solubility when placed in cold water (approximately 77° F.) and a high solubility dextrin typically exhibits about 90% or more solubility when placed in cold water (approximately 77° F.).

The typical moisture barrier slurry composition used in the coatings of the present invention contains corn dextrin in an amount of from about 2% to about 50% by weight of the coating composition, more typically from about 5% to about 30%, and most typically about 10% dextrin.

The moisture barrier slurry compositions applied to raw dough before or after proofing or to a fried doughnut of the present invention optionally also includes sucrose or other sweetening agents. When sucrose is utilized, the sucrose is typically added as a solute to control starch hydration in film formation. In appropriate amounts, sucrose imparts a sweet flavor, if desired. The sucrose is typically granular sucrose. When incorporated into the coating compositions of the present invention, the sucrose is typically present in an amount of from about 0% to about 30% by weight of the coating composition, more typically from about 3% to about 15%, and most typically at about 5%.

Additionally, the moisture barrier slurry compositions applied to raw dough before or after proofing or to a fried doughnut optionally include a natural or synthetic stabilizer such as a gum or a similar stabilizer, including, but not limited to, xanthan gum, guar gum, or CMC (carboxymethylcellulose). Mixtures of such stabilizers may also be used. When a stabilizer is utilized, the water-soluble moisture barrier slurry compositions typically utilize a xanthan gum such as KELTROL F™ available from Kelco Co. of Wilmington, Del. The xanthan gum or other stabilizer may be present in the amount of from about 0% to about 3% by weight of the coating composition, more typically from about 0.05% to about 1.0%, and most typically at about 0.15%.

The moisture barrier slurry compositions of the present invention applied to raw dough before or after proofing or to a fried doughnut optionally also include an emulsifier, such as lecithin, phospholipids, mono and di-glycerides, casienates. Typically lecithin is used. The lecithin is typically present in the amount of from about 0% to about 10% by weight of the coating composition, more typically from about 0.5% to about 5%, and most typically at about 1.5%.

Additionally, the moisture barrier slurry composition applied to raw dough before or after proofing or to a fried doughnut typically includes flour. The flour utilized may include wheat flour, rice flour, corn flour, potato flour, or any other commercially acceptable flour; however, rice flour is most typically used. The flour is believed to provide film forming functionality to the slurry composition. The flour of the slurry composition is typically present in the amount of from about 5% to about 50% by weight of the coating composition, more typically from about 10% to about 35%, and most typically at about 25%.

The wet slurry typically has a wet slurry solid contents of from about 35% to about 50%, and more typically at about 45%. The wet slurry solids parameter is an indication of the percentage of the slurry in solid physical form.

Dextrin Moisture Barrier Composition for Fried or Raw Dough Doughnuts

Alternately, the moisture barrier coating may only include a dextrin with water in a slurry form and may be applied to a wet slurry on proofed raw doughnut dough or on a fried doughnut. The preferred dextrin in this moisture barrier coating is a high-solubility dextrin (i.e., 90% or more solubility when placed in cold water (approximately 77° F.)). The dextrin has a solids content of approximately 50% solids at room temperature.

Application Process for Both the Typical and Dextrin Moisture Barrier Compositions

Raw Dough

When the moisture barrier slurry composition is utilized on raw (substantially uncooked) dough 10, it may be applied to by any industrially acceptable method, including, but not limited to, spray coating or a dunk/drip bath. However, the typical application method is a spray coating application that typically coats the entire doughnut dough. The wet slurry may also be applied to the raw dough substrate before or after proofing. One application process for moisture barrier compositions when applied to raw dough and fried doughnuts is shown in FIG. 1.

At whatever stage the moisture barrier is applied, the process typically begins by extruding doughnut dough and cutting the doughnut dough into individual doughnuts or alternatively by forming the dough substrate by any means 12. Each individually cut doughnut typically has a dough weight of from about 27 grams to about 34 grams. In one embodiment, the wet slurry is then sprayed onto the individually cut raw dough doughnuts 14. Optionally, the raw dough doughnuts may be transferred to a proofer prior to coating. In this instance, the moisture barrier composition is subsequently applied to the proofed raw dough. The wet slurry coated dough or, as yet uncoated, doughnuts are typically placed on sheets or trays prior to placement in the proofer. The proofer is an enclosed machine wherein temperature and humidity are modified to activate yeast. In this particular processing step, yeast is activated to make gas and therefore the dough rises or proofs. Typically, higher temperatures and greater humidity results in the dough rising more and gives larger doughnuts. Conversely, lower temperatures and less humidity results in the dough rising less yielding smaller doughnuts. If not previously coated, the raw dough doughnuts may be coated at this stage 16. Conceivably, coating after proofing could be a second coating, but coating at this stage is not typically a subsequent coating.

Once coated, either prior to or after proofing, the doughnuts are then fried 18. Any industrial acceptable fryer will work. The doughnuts are fried on both sides for from about 80 seconds to about 90 seconds at a typical temperature of from about 365° F. to about 375° F. More typically, the doughnuts are fried for about 86 seconds at a temperature of about 370° F. If not previously coated or if a subsequent coating is desired, which is not typically the case, the slurry should be applied to the doughnut after the raw dough is fried, but prior to glazing.

Typically, a hot or cold glaze or other coating may then be applied to the wet slurry coated doughnuts 20. The amount of glaze pickup or other coating pickup is typically measured in all application methods. The temperature of the glaze affects glaze pickup with cooler glazes resulting in more glaze pickup by the doughnut. The glaze pickup measures the amount of glaze, which does not fall off or drip from the doughnut after application. The glaze pickup percentage is determined via the following calculation: the glaze-coated weight of the glazed-coated doughnut minus the unglazed weight of the unglazed doughnut divided by the unglazed weight times 100. The glaze pickup of the glaze-coated doughnuts employing the moisture barrier of the present invention is typically from about 30% to about 47%.

The glazed or otherwise coated doughnuts are then cooled 22 even if a cool or cold glaze is used because the doughnut itself is still warm or hot. This is typically done by using cooled forced air. The cooled doughnuts are then packed into paperboard cartons, or other packing material and prepared to be shipped to their final destination 24.

Fried Doughnuts

The moisture barrier wet slurry may be applied to fried doughnuts 25 by any industrial acceptable method, including, but not limited to, spray coating or a dunk/drip bath. The typical method of application is a spray method of application which typically coats the entire doughnut. One application process for the moisture barrier composition when applied to a fried doughnut is shown in FIG. 2. This method of application typically begins by extruding doughnut dough and cutting the dough into individual doughnuts as discussed above 26. The individual extruded doughnuts are transferred to the proofer and proofed 28. The proofed doughnuts are then typically parfried on both sides 30 for about 20 seconds to about 50 seconds at a temperature of from about 365° F. to about 375° F. More typically, the proofed doughnuts are parfried on both sides for about 40 seconds at a temperature of about 370° F. The wet slurry is then sprayed onto the parfried doughnuts 32. As discussed above, the wet slurry typically has a wet slurry solid contents of from about 35% to about 50%. More typically, the wet slurry solids content is about 45%. The coated doughnuts are then finish fried 34 from about 20 seconds to about 50 seconds at a temperature of from about 365° F. to about 375° F. More typically, the doughnuts are finish fried for about 48 seconds at a temperature of about 375° F.

As discussed above, typically the next step is application of a glaze or other coating to the doughnut surface 36. The amount of glaze pickup or other coating pickup is typically measured in all application methods and is measured via the same method and calculation as discussed above. The glaze pickup for coated fried doughnuts is typically substantially similar to the glaze pickup discussed above, about 30% to about 47%. After glazing, the doughnuts may be cooled, using forced air 38. The cooled doughnuts may be packed into paperboard cartons or other industrial acceptable packing materials and prepared to be shipped to their final destination 40.

Typical Moisture Barrier Compositions for Fried, Cooled, Reheated Doughnuts

The moisture barrier in wet slurry form may also be applied to fried, cooled, and then reheated doughnuts. Typically, the clear coat moisture barrier in wet slurry form applied to fried, cooled, and reheated doughnuts includes a starch component, typically MIDSOL 35™ (an oxidized and acetylated wheat starch component) and/or a dextrin component, typically a potato dextrin component.

The modified wheat starch may be present in the moisture barrier in an amount of from about 50% to about 100% and most typically at about 100%. As previously mentioned, it is presently believed that other modified and/or unmodified starches such as corn starch, potato starch, and tapioca starch also form an at least partial moisture barrier, but modified wheat starch either alone or in combination with a potato dextrin is presently preferred when the moisture barrier coating composition is to be applied to a fried or parfried that typically is subsequently cooled prior to finish frying or reheating.

The modified wheat starch is typically used to provide viscosity, crispness and film formation. Such a wheat starch may be a modified wheat starch such as an oxidized and/or substituted wheat starch. Typically, the wheat starch used in the clear coat moisture barrier wet slurry for doughnuts is modified. The modification is typically an oxidized and substituted wheat starch that has a substitution level that typically ranges from about 0.01% to about 1%; however, the more typical substitution level is about 0.1%. One modified wheat starch that may be used in the clear coat moisture barrier wet slurry of the present invention is MIDSOL 35™, which can be purchased from Midwest Grain Products of Atchison, Kans.

The moisture barrier wet slurry may also, or alternatively, contain a dextrin. The dextrin utilized may include corn dextrin, tapioca dextrin, and potato dextrin; however, potato dextrin is most typically used. The dextrin is believed to provide superior film forming functionality to the coating composition. All dextrins are soluble to some degree; however, a low solubility dextrin is typically used in the present invention. The typical clear coat moisture barrier wet slurry used to coat doughnuts contains from about 50% to about 100% potato dextrin, and more typically about 100% potato dextrin. One source of potato dextrin is EMDEX™ potato dextrin available from Emsland Staerke, Gmbh of Germany.

Application Processes for the Moisture Barrier Compositions When Applied to Fried, Cooled and Reheated Doughnuts

As in the case of the raw dough and fried dough application processes discussed above, the typical method of application of the moisture barrier wet slurry to the fried or parfried, cooled, and then reheated doughnuts 41 utilizes a spray method that typically coats the entire doughnut. Conceivably though and as with these other processes, some advantages and benefits of the present invention could be achieved by coating only a portion of the doughnut, i.e. the portion to have the most glaze or other coating applied to it. One application process for the moisture barrier composition when applied to a fried, cooled, and reheated doughnut is shown in FIG. 3.

The method of applying the slurry to the fried or parfried, cooled, and reheated doughnuts typically begins by forming the doughnut or similar substrate as discussed earlier with regard to other processes 42. Once formed, the extruded doughnuts are then typically placed on sheets or trays and then placed in a proofer 44. Proofed doughnuts are then fried on both sides 46 from about 80 seconds to about 90 seconds at a temperature of from about 365° F. to about 375° F. More typically, the proofed doughnuts are fried on both sides for about 86 seconds at a temperature of about 370° F. The doughnuts are then cooled 48 to a temperature of typically less than 100° F., more typically to a temperature of about 80° F. At this stage, the doughnuts may be frozen or otherwise stored if desired or required. The doughnuts are then reheated or thawed and reheated 50 to a surface temperature of typically greater than 160° F. and more typically to a temperature of about 210° F. Thereafter, the clear coat moisture barrier wet slurry may be sprayed onto the parfried doughnuts 52.

The wet slurry typically has a wet batter solids content of from about 20% to about 55%, but more typically the wet batter solids content is about 50%. The wet slurry coated doughnuts are then baked 54 at a temperature of typically from about 200° F. to about 450° F. for about 2 to about 6 minutes, or more typically baked at a temperature of about 400° F. for about 3 minutes, or until the wet slurry is set. A glaze or other coating may then be applied to the coated surface of the doughnut 56. The glaze pickup is typically from about 30% to about 47%. The glazed doughnuts are then cooled. Typically the glazed doughnuts are cooled using forced air 58. The cooled clear coated and glazed or otherwise frosted or coated doughnuts are packed into paperboard cartons, or other industrial acceptable packing material and prepared for shipment to their final destination 60.

Dry Dusting

Instead of being applied as a slurry, the moisture barrier composition may also be dry dusted onto doughnuts or other dough-based goods. Currently, the dry dusting method is generally preferred primarily due to the significant processing advantages over using a wet slurry application. Like the slurry composition, the moisture barrier dry dusting compositions of the present invention may be applied to dough, fried products, parfried products and/or fried, cooled, then reheated products as well as frozen, thawed, and reheated products. Also the dry dusting compositions are typically clear coat moisture barrier dry dusting compositions.

Moisture Barrier Compositions for Raw Dough Doughnuts

The moisture barrier composition for dry dusting raw dough before proofing and frying doughnuts or other pastry products typically includes a dextrin component such as EMDEX™, a potato dextrin. Typically, when the moisture barrier coating composition is applied as a dry dusting on raw dough a dextrin component is the only ingredient of the composition. The dextrin component, typically potato dextrin, is usually present in the clear coat moisture barrier dry dusting composition in an amount of from about 20% to about 100% by weight of the coating composition; more typically from about 50% to about 100%, and most typically at about 100%.

The dextrin utilized may include corn dextrin, tapioca dextrin, and/or potato dextrin; however, potato dextrin is most typically used. Any potato dextrin may be used.

Application Processes for the Moisture Barrier Compositions when Applied to Raw Dough

The moisture barrier dry dusting composition may be applied to doughnuts by any known industrial acceptable method. However, typically substantially all of the doughnut or other dough-based products should be dry dusted. Conceivably, as with wet slurries, coating only a portion (i.e. the portion of the doughnut or other pastry product to be coated) of the doughnut would provide at least some of the benefits of the present invention.

One application process for the dry dusting moisture barrier when applied to raw dough before or after proofing 61 is shown in FIG. 4. When applied at any stage, dry dusting the raw dough, typically begins by forming the doughnut as discussed earlier 62. Once the doughnut is formed, the dry dusting mixture is dusted onto the doughnut dough 64. The dry dusting mixture may be applied to the doughnut dough as the doughnut dough passes on a horizontal conveyor under a hopper-like machine. Within the hopper are two horizontal rotating bars that extend from one end of the hopper to the other. These bars are scored along the length of the bars so that one or more valleys exist. As the bars rotate, the valleys facing upwards, or away from the doughnut dough, fill with a dry dusting composition of the present invention. The bars rotate along a horizontal axis. As the bars containing dry dusting composition filled valleys turn approximately one quarter turn, the valleys engage a bristled brush. The bristled brush is positioned close enough to the rotating bars so that when the bars engage the brush, the bristles bend while the bristle tips remain in the valley. As the bars rotate further, the brush tilts downward and the bristles essentially project the coating into the doughnut dough below. Such a coating machine may be purchased from CHRISTY® Machine Company of Fremont, Ohio.

The amount of dry dusting pickup is typically measured in all application methods. The dry dusting pickup measures the amount of the moisture barrier dry dusting composition that does not fall off the doughnut after application. The dry dusting pickup percentage is determined via the following calculation: the coated weight of the coated doughnut minus the uncoated weight of the uncoated doughnut divided by the uncoated weight times 100. The moisture barrier dry dusting mixture of the present invention, when applied to a doughnut, typically attains a percentage pickup of from about 0.2% to about 5%, but more typically about 2% pickup.

The coated doughnuts are then transferred to the proofer 66. While not preferred, the doughnut can also be coated with dry dusting coating mixture after the raw dough has been proofed and prior to frying. The proofed doughnuts are then fried on both sides 68 for typically from about 80 seconds to about 90 seconds at a temperature of from about 365° F. to about 375° F., and more typically at about 86 seconds at a temperature of about 370° F. The glaze or other coating is then applied to the coated doughnut surface 70. The glaze pickup is from about 30% to about 47%. The glazed or otherwise coated doughnuts are then cooled, typically using forced air 72. The cooled doughnuts are then packed into paperboard cartons, or other industrial acceptable packing material, and prepared for shipment to their final destination 74.

Moisture Barrier Compositions for Fried Doughnuts

The moisture barrier dry dusting composition may also be applied to a fried doughnut. Typically, the moisture barrier dry dusting composition for dry dusting a fried doughnut includes C*POLARTEX-INSTANT 12640™ or HIFORM™ (pregelatinized, stabilized, crosslinked waxy maize starch).

The pregelatinized, stabilized, crosslinked waxy maize starch is typically present in the moisture barrier dry dusting composition from about 20% to about 100% by weight of the coating composition, more typically from about 50% to about 100%, and most typically at about 100%.

Pregelatinized, stabilized, crosslinked waxy maize starch may be used to provide a continuous, invisible or nearly invisible film on a fried doughnut. One pregelatinized, stabilized, crosslinked waxy maize starch used as the water-soluble moisture barrier dry dusting composition of the present invention for application to a fried doughnut or other pastry product is C*HIFORM™, which can be purchased from Cargill of Minneapolis, Minn. Typically, when applied as a dry dust to fried doughnuts, a starch component is the only ingredient of the composition. The use of C*HIFORM™ starch as the dry dusting composition extended the shelf-life of the final doughnut at least to about 2 to about 5 days. Another pregelatinized, stabilized, crosslinked waxy maize starch that may be used as the water-soluble moisture barrier dry dusting composition of the present invention is C*POLARTEX-INSTANT 12640™, which may be purchased from Cargill of Minneapolis, Minn. When used, the C*POLARTEX-INSTANT 12640™ extended the shelf life of the final doughnut products to at least about 5 to about 6 days. Of course, mixtures of these starches may also be used. Moreover, as discussed previously, it is believed other starches either alone or in combination will exhibit at least some of the features of the present invention, but in the case of coating fried doughnuts, pregelatinized, stabilized, crosslinked waxy maize starch is preferred.

Application Processes for the Moisture Barrier

Compositions when Applied to a Fried Doughnut

The clear coat moisture barrier dry dusting composition may be applied to the doughnut by any industrial acceptable method. One application process for the dry dusting moisture barrier when applied to a fried doughnut 75 is shown in FIG. 5. The first step, as discussed earlier, is to form a doughnut from dough 76. The doughnuts are then transferred to a proofer 78. The proofed doughnut dough is then fried on both sides 80 typically for about 80 seconds to about 90 seconds at a temperature of from about 365° F. to about 375° F., and more typically for about 86 seconds at a temperature of about 370° F. The clear coat moisture barrier dry dusting composition is dry dusted on the surface of a hot doughnut 82. The surface temperature of the hot doughnut is typically greater than 160° F. and more typically about 210° F. It is believed the hot surface facilitates film formation, but it is not believed to be a requirement that the doughnut be hot when dry dusted. When applied to a fried doughnut, the dry dusting pickup percentage is typically from about 0.2 to about 5% and more typically from about 0.5% to about 0.8%. The dry dusted doughnuts are then transferred to a coating machine, typically a glazer 84. The coated doughnuts are transferred to the glazer for about 5 seconds to about 120 seconds and more typically for about 20 to about 50 seconds. It is believed that this time to the glazer enhances film formation and facilitates development of the moisture barrier on the coated doughnuts. A glaze or other coating, which is generally applied at a temperature of from about 105° F. to about 140° F. and more typically at about 115° F. to about 120° F., is then applied to the dry dusted doughnut surface 86. The glaze pickup percentage is usually from about 30% to about 47%. The glazed or otherwise coated doughnuts are then cooled, typically using forced air 88. The cooled doughnuts are then packed into paperboard cartons, or other industrial acceptable packing material, and prepared for shipment to their final destination 90.

Moisture Barrier Compositions for Parfried or Fried, Cooled, Reheated Doughnuts

The moisture barrier dry dusting composition may also be applied to parfried or fried, cooled, then reheated doughnuts. When applying the moisture barrier dry dusting composition of the present invention to parfried or fried, cooled, then reheated doughnuts, the coating composition typically includes an oxidized, pregelatinized, modified tapioca starch. Typically, when applied as a dry dust to parfried or fried, cooled, reheated doughnuts, the starch component is the only ingredient of the moisture barrier composition. It is presently believed that other starches such as corn starch, potato starch, wheat starch and mixtures of these starches and tapioca starch may also provide some of the benefits of the present invention in this application method and the method of dry dusting a fried finished doughnut, as will be discussed later. However, when coating fried or parfried, cooled, and then reheated doughnuts, pregelatinized and chemically modified tapioca starch is presently preferred and, when coating fried doughnuts pregelatinized corn starch is presently preferred.

The pregelatinized and chemically modified tapioca starch is typically present in the water-soluble moisture barrier dry dusting composition from about 20% to about 100% by weight of the coating composition, more typically from about 50% to about 100%, and most typically at about 100%.

The pregelatinized, chemically modified tapioca starch may be used to provide a continuous, substantially invisible film on a fried, cooled, then reheated doughnut.

Application Processes for the Moisture Barrier Composition when

Applied to a Parfried or Fried, Cooled and Reheated Doughnut

The moisture barrier dry dusting composition may be applied to fried or parfried, cooled, then reheated doughnuts using any industrial acceptable method. One application process for the dry dusting moisture barrier when applied to a fried, cooled and reheated doughnut 91 is shown in FIG. 6. As discussed previously regarding other methods of application, this application method typically begins by extruding and cutting doughnut dough into individual doughnuts 92. The doughnut dough may then be transferred to a proofer 94. The proofed doughnut dough is then fried on both sides 96 typically for from about 80 seconds to about 90 seconds at a temperature of about 365° F. to about 375° F., and more typically for about 86 seconds at a temperature of about 370° F. Typically, the doughnuts are then cooled 98 to a temperature less than about 100° F., more typically to a temperature of about 80° F. At this stage, the doughnuts may be frozen or otherwise stored if desired or required. The doughnuts are then reheated 100 to a surface temperature of typically greater than 160° F. and more typically to a temperature of about 210° F. The moisture barrier dry dusting composition is applied to the surface of a hot doughnut 102. The dry dusting composition may be applied by any industrially acceptable method or as described above for example by using a coating machine as purchased from CHRISTY® Machine Company of Fremont, Ohio. The percentage of dry dusting pickup is typically from about 0.2% to about 5% and more typically from about 0.5 to about 0.8%. The dry dusted doughnuts are then transferred to a coating machine, typically a glazer 104. Prior to actual application of a glaze or other coating, the doughnuts are transferred to the glazer for typically from about 5 to about 120 seconds and more typically for about 20 to about 50 seconds. This time to the glazer or other coating machine is believed to further enhance film formation of the coating. A hot glaze is then applied to the dry dusted doughnut surface 106. The hot glaze pickup is typically from about 30% to about 47%. The glazed or otherwise coated doughnuts are then cooled, typically by forced air 108. The cooled doughnuts are then packed into paperboard cartons, or other industrial acceptable packing material, and prepared to be shipped to their final destination 110.

EXAMPLES

The following examples more precisely and particularly illustrate the specific details of the present invention. Equivalent procedures and quantities will occur to those skilled in the art and, therefore, the following examples are not meant to define the limits of the present invention, these being defined by the scope of the appended claims. The object of these examples was to prepare a moisture barrier coated doughnut in a laboratory environment, wherein the moisture barrier was not readily visible on the doughnut, but provided at least a partial barrier to moisture transfer that otherwise occurs between the dough portion and the glazed portion of the finished doughnut due to the water activity gradients present without significantly increasing the fat content of the doughnut.

Example 1

The object of this example was to determine an acceptable wet slurry moisture barrier formula when applied on raw dough before or after proofing. The ingredients utilized in the wet slurry moisture barrier coating in this example include:

Formula 1

Ingredient % Formula Modified potato starch component 56.65 Sodium acid pyrophosphate (leavening agent) 1.00 Sodium bicarbonate (leavening agent) 0.70 Xanthan gum (stabilizer) 0.15 Dextrin 10.00 Lecithin (emulsifier) 1.50 Rice flour 25.00 Sucrose 5.00

Method:

-   1. Dough was extruded and cut into individual doughnuts—raw doughnut     weight is about 27 grams to about 37 grams; -   2. The clear coat moisture barrier composition was sprayed onto raw     doughnuts using a spray bar; -   3. Doughnuts are transferred to the proofer either before or after     they were coated with the clear coat moisture barrier composition.     If doughnuts were transferred to the proofer before they were coated     with the clear coat moisture barrier composition, the doughnuts were     then proofed and subsequently coated with the clear coat moisture     barrier before they are fried; -   4. The proofed doughnuts were fried on both sides; -   5. The glaze was applied to the doughnut surface that has been     coated with the clear coat moisture barrier composition; -   6. The glazed doughnuts were then cooled using forced air; and -   7. The cooled doughnuts were then packaged into paper board cartons     or other suitable containers.

In this example the doughnut did not have increased crispness, however the coating did stabilize the glaze. Ordinarily, without using a clear coat moisture barrier composition the glaze will start to liquefy at about 24 hours. By using a clear coat moisture barrier composition of the present invention the shelf-life of the coated doughnut is extended to 4 or more days.

The Stein (top to first break in stream of slurry material) viscosity measurement was approximately 14.7 seconds. The slurry viscosity is typically measured by the industry Stein testing procedure outlined below:

-   1. Completely fill a clean, dry Stein cup with slurry (using a     fingertip to act as a stopper to prevent the slurry from draining     out the bottom of the cup hole); -   2. Use other hand to hang onto the wire handle of the Stein cup and     to hold the stopwatch; -   3. Remove finger covering the bottom cup hole and simultaneously     start stopwatch. Stop the watch when the slurry stream passing     through the bottom cup hole first breaks the continuous stream; -   4. Record the time in seconds; and -   5. Repeat this procedure two additional times. Calculate the average     of the three determinations and record.

The percentage of slurry solids in Example 1 was approximately 45%. The moisture barrier wet slurry composition of Formula 1 stabilized the glaze in the wet slurry coated and glazed doughnut.

Example 2

In this example a wet slurry was applied to a fried doughnut. The ingredients utilized in the wet slurry moisture barrier in this example include:

Formula 2

Ingredient % Formula Modified potato starch component 56.65 Sodium acid pyrophosphate (leavening agent) 1.00 Sodium bicarbonate (leavening agent) 0.70 Xanthan gum (stabilizer) 0.15 Dextrin 10.00 Lecithin (emulsifier) 1.50 Rice flour 25.00 Sucrose 5.00

Method:

-   1. The dough was extruded and cut into individual doughnuts—raw     doughnut weight is about 27 grams to about 34 grams; -   2. The doughnuts were transferred to a proofer; -   3. The proofed doughnuts were parfried on both sides; -   4. The clear coat moisture barrier composition was sprayed onto the     parfried doughnuts; -   5. The doughnuts were finished fried; -   6. The glaze was applied to the doughnut surface that has been     coated with the clear coat moisture barrier composition; -   7. The glazed doughnuts were then cooled using forced air; and -   8. The cooled doughnuts were then packaged into paper board cartons     or other suitable containers.

The percentage of slurry solids in Example 2 is approximately 45%. The Stein (top to first break in stream of slurry material) viscosity measurements were approximately 14.56, 14.66 and 14.71 seconds with the Stein average being approximately 14.64 seconds.

Regarding step 4 of the method described immediately above, the doughnuts were coated with the clear coat moisture barrier composition by using a spray bottle to spray the composition onto the doughnuts that had been fried for approximately 10 seconds on both sides. The clear coat moisture barrier composition coated doughnuts were then placed back into the fryer to finish frying. The clear coat moisture barrier had some visibility where the surface was cracked and peeled back under the glaze (e.g. bumpy). The cooled coated doughnuts were then set aside to determine their shelf-life. On days 1 and 2 there was no wetting out. The term “wetting out” indicates a water activity gradient between the doughnut portion and the glaze portion where over the course of time water from the portion having a higher water activity migrates to the portion having a lower water activity. Typically, the doughnut portion has a higher water activity than the glaze portion, therefore, absent a moisture harrier, water migrates from the doughnut portion to the glaze portion causing at least spots of wetting out in the glaze.

In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise. 

1. A bakery product comprising: a substantially uncooked doughnut substrate at least partially derived from dough or batter, wherein the dough or batter is at least partially derived from wheat; and a dry coating composition comprising: from about 50% to about 100% potato dextrin; wherein the dry coating composition at least partially covers the surface of the dough prior to application of a second coating and the dough and the second coating have different water activities and the dry coating composition provides a moisture barrier between the doughnut dough and the second coating. 